Overhead Crane Installation to Support Increased Production
This project involved the installation and commissioning of a 2 tonne underslung overhead crane to support increased operational demand within an expanded industrial workshop facility. The installation demonstrates our capability in delivering complete overhead crane installation services for engineering and manufacturing environments across the UK.
Following relocation into a larger premises, the client required additional lifting capability to maintain efficient workflow and support increased servicing and assembly throughput. The facility previously operated with a single overhead crane, which created operational bottlenecks when multiple lifting operations were required simultaneously.
The Challenge
The client’s workshop operations involve handling specialist industrial components, including assemblies associated with valve and pump servicing. The facility previously relied on a single overhead crane, creating operational bottlenecks when multiple lifting tasks were required at the same time.
The installation also needed to be completed within a live working environment, requiring careful planning and coordination to ensure safe working practices while minimising disruption to ongoing operations.
Overhead Crane Installation Requirement
The client’s workshop supports the handling and servicing of specialist industrial components, including assemblies associated with valve and pump operations. As workload increased, the existing lifting solution no longer provided sufficient coverage or availability.
The requirement was to install a second overhead crane that would:
- Increase lifting availability within the facility
- Improve workflow efficiency and reduce operational delays
- Provide reliable and precise load handling
- Integrate safely within an active working environment
The Solution
A 2 tonne underslung single girder overhead crane was designed to maximise lifting coverage while optimising available headroom within the building structure and included:
- 2 tonne Safe Working Load (SWL)
- 23 metre span providing extensive workspace coverage
- Low headroom wire rope hoist to maximise available lifting height
- Dual-speed hoisting for precise load handling
- Variable speed cross and long travel motions for smooth, controlled movement
- Radio control operation with backup pendant control
- IP54 rated electrics suitable for industrial environments
- 4-bar conductor rail system for reliable power distribution
The crane was supplied complete with full certification, documentation, and load testing to 125% of SWL, ensuring compliance with industry safety standards.
Crane Installation & Commissioning Process
The project was delivered through a collaborative installation approach, ensuring efficient delivery while maintaining safe operations within a live workshop environment.
Mechanical installation included:
- Landing and positioning of the crane bridge beam onto runway rails
- Installation of hoist and end carriage assemblies
- Installation of conductor rail power supply system
Electrical installation and commissioning included:
- Connection of crane electrics and power supply
- Integration of control systems
- Full functional testing of crane movements
- Load testing using calibrated test weights
- Issue of Thorough Examination and Test Certification
Despite installation taking place within an operational facility, the project was completed safely and efficiently through close coordination with site personnel. Full installation and commissioning were successfully completed within four days.
The Result
The additional overhead crane has significantly enhanced operational efficiency within the facility by allowing multiple lifting operations to be performed simultaneously. This has reduced workflow delays and improved overall productivity within the workshop.
Key benefits delivered include:
- Increased lifting availability and reduced operational bottlenecks
- Improved handling efficiency for service and assembly activities
- Greater operational flexibility within the expanded facility
- Safe installation completed with minimal disruption to site operations
Delivering Reliable Lifting Solutions
This project demonstrates our ability to deliver complete lifting solutions, from equipment supply through to installation, commissioning, and certification. By working alongside trusted installation partners and maintaining a strong focus on safety, efficiency, and compliance, we help clients maximise productivity and operational performance.
We provide complete overhead crane installation and commissioning services, supporting projects across engineering, manufacturing, offshore, and industrial sectors. Our services include mechanical installation, electrical commissioning, load testing, certification, and ongoing support. Learn more about our installation capabilities here.